Process to manufacture a reaction resin cement building material mixture

Abstract

The invention concerns a process to manufacture a building material mixture from a reaction resin, a hardener, cement, an aggregate containing coarser and finer parts and water. To produce a storage stabile, dry premix the coarser parts of at least one partial amount of the aggregate are mixed with the liquid resin or the liquid hardener such, that droplets or films of the resin, resp. hardener can adhesively deposit themselves on the surfaces of the coarsely-grained aggregate, subsequently the finer parts of the aggregate are added, which cover the remaining free surfaces of the droplets, resp. films, or that for the manufacture of a storage stabile, dry mix an amount of liquid resin or hardener is cooled until the amount solidifies, in this state is ground to powder and is mixed with the finest fraction of the aggregate before the powdery resin, resp. hardener again return to its liquid state.

I claim: 
     
       1. A process for the manufacture of a building material from reaction materials in the form of a storage stable premix which comprises: preparing a dry premix (A) by first coating aggregate material with a liquid epoxy resin by mixing said resin with said aggregate material under conditions such that the epoxy resin is deposited on and adhered to the surface of the aggregate;   coating the resulting epoxy coated aggregate with a pulverized aggregate powder thereby covering the epoxy coated aggregate;   preparing a dry mix (B) by coating aggregate material with an epoxy resin hardener such that a film of the hardener is deposited on and adhered to the surface of the aggregate material and then coating the resultant hardener coated aggregate with a pulverized aggregate powder whereby a covering film is formed over the epoxy resin hardener coated aggregate; and,   mixing premix (A) with premix (B) to form said building material.   
     
     
       2. In a process for the manufacture of a building material from reaction materials including an epoxy resin component and an epoxy resin hardener component and aggregate, the improvement which comprises: utilizing a premix component formed by cooling either a liquid epoxy resin or a liquid epoxy resin hardener or both separately until solid;   grinding either of said resultant solidified epoxy resin or solidified epoxy resin hardener or both to a powder; and,   contacting the resultant epoxy resin powder or epoxy resin hardener powder, or both, with pulverized aggregate for forming a coating over said epoxy resin or epoxy resin hardener or both.   
     
     
       3. The process of claim 1 further comprising adding and mixing cement with the coated epoxy resin powder in premix A or coated epoxy resin hardener in premix B. 
     
     
       4. The process of claim 1, wherein proportions of the resin and the hardener and proportions of the aggregate respectively contained in premix A and premix B are chosen such that equal volumes of premix A and premix B produce a complete resin and hardener reaction when mixing both volumes. 
     
     
       5. The process of claim 1, wherein said mixing is accomplished with an aggregate having granules with inert surfaces, whereby the reaction material is not diffused into the aggregate. 
     
     
       6. The process of claim 1, further comprising the step of adding an emulsifying agent prior to mixing said epoxy resin or epoxy resin hardener with the aggregate. 
     
     
       7. The process of claim 1, wherein the epoxy resin and epoxy resin hardener are mixed at a weight percent of 5 to 20 weight percent of said mixture. 
     
     
       8. The process of claim 1, wherein the resin is bisphenol A epoxy resin. 
     
     
       9. The process of claim 7, further comprising the step of adding cement to the mixture, and wherein the cement comprises approximately 12 weight percent of the mixture.